Decorative stainless steel rolled sheet with embossed patterns and method of manufacturing the same

Abstract

A decorative stainless steel rolled sheet has an embossed pattern, suitable for use as a surface finish or an interior surface finish of products, wherein a thin stainless steel sheet subjected to surface treatment including nanoceramic coating or PVD ionic coating resulting in various colors and a release sheet alone or with a nonwoven fabric layer bonded thereto by means of a hot melt adhesive layer are embossed together and bonded to each other with the embossed pattern, thus exhibiting superior bonding strength, heat resistance, fire resistance, scratch resistance, shape stability, flexibility and wrinkling resistance. In the method of manufacturing such a decorative stainless steel rolled sheet, the rolled sheet can be mass produced at uniform quality using a continuous process.

What is claimed is: 
     
       1. A method of manufacturing a decorative stainless steel rolled sheet having an embossed pattern, comprising:
 unwinding a thin stainless steel sheet, having a thickness of 0.05 to about 0.15 mm and subjected to a surface treatment having selected from the group consisting of nanoceramic coating and PVD (Physical Vapor Deposition) ionic coating, from a thin stainless steel sheet take-up roll and feeding it between first feed rolls; 
 applying a hot melt adhesive on one side of the thin stainless steel sheet, which moves by means of the first feed rolls, using an adhesive feed roll and the first feed rolls, thus forming a hot melt adhesive layer on one side of the thin stainless steel sheet; 
 
       unwinding a release sheet having a thickness of 0.05 to about 0.10 mm and made of a polyethylene or polypropylene film from a release sheet take-up roll and feeding it between second feed rolls so that it is bonded onto the hot melt adhesive layer formed on one side of the thin stainless steel sheet;
 embossing the thin stainless steel sheet and the release sheet bonded thereto by means of the hot melt adhesive layer using an emboss roll composed of a positive pattern roll and a smooth roll, thus forming the embossed pattern; 
 winding a resulting product in rolled sheet form on a take-up roll; and 
 bonding a double-sided adhesive sheet having release paper on one side thereof to the hardened hot melt adhesive layer, after the release sheet has been removed. 
 
     
     
       2. The method as set forth in  claim 1 , further comprising bonding a nonwoven fabric layer having a thickness of 0.05 to about 10 mm onto the hot melt adhesive layer formed on one side of the thin stainless steel sheet. 
     
     
       3. The method as set forth in  claim 1 , wherein the hot melt adhesive layer is formed to have a thickness of 0.05 to about 0.012 mm. 
     
     
       4. The method as set forth in  claim 1 , wherein the embossed pattern is formed to have a depth of 50 to about 200 μm. 
     
     
       5. A method of manufacturing a decorative stainless steel rolled sheet having an embossed pattern, comprising:
 unwinding a thin stainless steel sheet, having a thickness of 0.05 to about 0.15 mm and subjected to a surface treatment having selected from the group consisting of nanoceramic coating and PVD (Physical Vapor Deposition) ionic coating, from a thin stainless steel sheet take-up roll and feeding it between first feed rolls; 
 applying a hot melt adhesive on one side of the thin stainless steel sheet, which moves by means of the first feed rolls, using an adhesive feed roll and the first feed rolls, thus forming a hot melt adhesive layer on one side of the thin stainless steel sheet; 
 
       unwinding a release sheet having a thickness of 0.05 to about 0.10 mm and made of a polyethylene or polypropylene film from a release sheet take-up roll and feeding it between second feed rolls so that it is bonded onto the hot melt adhesive layer formed on one side of the thin stainless steel sheet;
 embossing the thin stainless steel sheet and the release sheet bonded thereto by means of the hot melt adhesive layer using an emboss roll composed of a positive pattern roll and a smooth roll, thus forming the embossed pattern; 
 winding a resulting product in rolled sheet form on a take-up roll; and 
 forming an additional adhesive layer on the hardened hot melt adhesive layer and bonding a sheet member comprising an aluminum sheet or a plating steel sheet having a thickness of 0.2 to about 1.2 mm onto the additional adhesive layer, after the release sheet has been removed.